Headlamp adjuster configured to prevent over-travel of an adjuster output shaft

ABSTRACT

A headlamp adjuster which includes an adjuster output shaft which is engageable with a reflector of a headlamp assembly. The adjuster output shaft extends from a housing, and the headlamp adjuster is configured such that in an overload condition, the adjuster output shaft is prevented from translating substantially axially, thereby reducing the risk of damage resulting from over-travel of the adjustor output shaft.

BACKGROUND

[0001] The present invention relates generally to headlamp adjusters which are used to adjust the position of a reflector of an automobile headlamp assembly, and relates more specifically to a headlamp adjuster which includes an overload clutch mechanism.

[0002] Modern day headlamps for vehicles are engineered and designed to be aerodynamically efficient. In this regard, the headlamps are designed as sealed assemblies wherein the portion of the headlamp approximate the outer surface of the automobile is relatively stationary, and is aerodynamic.

[0003] A typical modern day headlamp assembly 12 is illustrated in a plan view seen as FIG. 1, and normally includes: a fixed housing 20, to which an outer headlamp lens 22 is affixed; a movable reflector 24, which is mounted within the fixed housing 20; and a stationary headlamp bulb (not shown), which is positioned within the movable reflector 24. Typically, the movable reflector 24 is mounted to the housing 20 by a universal or ball-type pivot 26 which is stationary, or fixed, on the housing 20.

[0004] A first pivot point 28 is disposed generally vertical of the fixed pivot 26, and a second pivot point 30 is disposed generally horizontal of the fixed pivot 26. As such, the movable reflector 24 may be pivoted about the fixed pivot 26 in the vertical and horizontal planes to aim the headlamp beam. Adjustment mechanisms, or headlamp adjusters, 40 and 42 are typically provided at the first and second pivot points, 28 and 30, normally termed the vertical pivot and the horizontal pivot, and the headlamp adjusters 40 and 42 can be operated to effect movement of the reflector 24 in the vertical and horizontal planes.

[0005] The headlamp adjusters 40 and 42 are typically mounted to the housing 20 of the headlamp assembly 12 and have adjuster output shafts 44, 46 operatively connected to the movable reflector 24 by ball and socket type pivots, or the like, such that linear movement of the adjuster output shafts 44, 46 produces pivoting of the movable reflector in the vertical and horizontal planes. Specifically, each headlamp adjuster 40, 42 typically includes drive structure 48, 50 for receiving a tool, and typically the drive structure 48, 50 is precision geared to the adjuster output shaft 44, 46. The gearing provides that using the tool to rotate the drive structure 48, 50 causes linear translation of the adjuster output shaft 44, 46 and therefore adjustment of the position of the headlamp reflector 24.

[0006] Before an automobile is released to the consumer, the movable reflectors of the headlamp assemblies are adjusted to a desired position so that the headlamp beams are properly aimed in both the vertical and horizontal directions. To this end, headlamp adjusters are normally operated at the automobile assembly plant. Thereafter, if a movable reflector moves from its desired position, due, for example, to vibration, jarring, or the vehicle being in an accident, a mechanic can operate the headlamp adjusters in order to properly re-align the reflectors.

[0007] Typically, headlamp adjusters are structured such that over-travel of the adjuster shafts (i.e. 44 in FIG. 1) is not prevented. Over-travel of the adjuster shaft can cause breakage of the headlamp adjuster housing and/or the reflector to which the adjuster shaft is connected. Specifically, over-extension of the adjuster screw from the housing can damage the reflector, and over-retraction of the adjuster screw into the housing can cause the end of the adjuster screw to contact an interior wall of the housing and result in damage to the housing, such as cracking. A crack in the housing can permit moisture, dirt, etc. to enter the housing which is undesirable.

OBJECTS AND SUMMARY

[0008] Accordingly, it is an object of an embodiment of the present invention to provide a headlamp adjuster which is structured such that over-travel of the adjuster output shaft is generally prevented.

[0009] Another object of an embodiment of the present invention is to provide a headlamp adjuster which includes an overload clutch mechanism which generally prevents over-travel of the adjuster output shaft.

[0010] Briefly, and in accordance with one or more of the foregoing objects, the present invention provides a headlamp adjuster which includes an adjuster output shaft which is engageable with a reflector of a headlamp assembly. The adjuster output shaft extends from a housing, and the headlamp adjuster is configured such that in an overload condition, the adjuster output shaft is prevented from translating substantially axially, thereby reducing the risk of damage resulting from over-travel of the adjustor output shaft.

[0011] Although a few embodiments and alternatives are discussed herein, it should be understood that modifications may be made thereto while staying within the scope of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The organization and manner of the structure and function of the invention, together with further objects and advantages thereof, may be understood by reference to the following description taken in connection with the accompanying drawings, wherein:

[0013]FIG. 1 is a plan view of a typical headlamp assembly;

[0014]FIG. 2 is a side view, in partial cross-section, of a headlamp adjuster which is in accordance with an embodiment of the present invention;

[0015]FIG. 3 is a front, elevational view of the headlamp adjuster shown in FIG. 2;

[0016]FIG. 4 is a perspective view of a bushing of the headlamp adjuster shown in FIGS. 2 and 3;

[0017]FIG. 5 is a top, plan view of the bushing shown in FIG. 4;

[0018]FIG. 6 is a side, elevational view of the bushing shown in FIG. 4;

[0019]FIG. 7 is a front, elevational view of the bushing shown in FIGS. 4-6;

[0020]FIG. 8 is a cross-sectional view of the bushing shown in FIGS. 4-7, taken along line 8-8 of FIG. 6;

[0021]FIG. 9 is a cross-sectional view of the bushing shown in FIGS. 4-8, taken along line 9-9 of FIG. 7;

[0022]FIG. 10 is a side view, in partial cross-section, of a headlamp adjuster which is in accordance with another embodiment of the present invention;

[0023]FIG. 11 is a front, elevational view of the headlamp adjuster shown in FIG. 10;

[0024]FIG. 12 is an exploded perspective view of a headlamp adjuster which is in accordance with still yet another embodiment of the present invention;

[0025]FIG. 13 is a side, elevational view, partially in section, of an output gear, retaining member and clutch bushing configuration which is used in connection with the headlamp adjustor which is shown in FIG. 12;

[0026]FIG. 14 is a side, elevational view, partially in section, of a rear portion of the headlamp adjuster shown in FIG. 12;

[0027]FIG. 15 is a rear, cross-sectional view of the headlamp adjuster shown in FIG. 12, taken along line 15-15 of FIG. 14; and

[0028]FIG. 16 is a top plan view of a headlamp adjuster which is in accordance with still yet another embodiment of the present invention.

DESCRIPTION OF EMBODIMENTS

[0029] While the present invention may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, embodiments of the invention with the understanding that the present description is to be considered an exemplification of the principles of the invention and is not intended to limit the invention to that as illustrated and described herein.

[0030] Shown in the FIGURES are several different headlamp adjusters which are in accordance with the present invention. Specifically, FIGS. 2 and 3 illustrate a headlamp adjuster 100 a which is in accordance with a first embodiment of the present invention, FIG. 10 and 11 illustrate a headlamp adjuster 100 b which is in accordance with a second embodiment of the present invention, FIG. 12 illustrates a headlamp adjuster 100 c which is in accordance with a third embodiment of the present invention, and FIG. 16 illustrates a headlamp adjuster 100 d which is in accordance with a fourth embodiment of the present invention. Each headlamp adjuster 100 a, 100 b, 100 c, 100 d is configured for engagement with the reflector of a headlamp assembly (see FIG. 1). As will be described, each headlamp adjuster 100 a, 100 b, 100 c includes an overload clutch mechanism which generally prevents over-travel of an adjuster output shaft 104 a, 104 b, 104 c. Headlamp adjuster 100 d includes a collar stop which generally prevents over-travel of an adjuster output shaft 104 d, and may also include an overload clutch mechanism.

[0031] The headlamp adjuster 100 a which is shown in FIGS. 2 and 3 will be described first, and then the other three headlamp adjusters 100 b, 100 c and 100 d will be described. In the following description, like reference numerals are used to identify like parts, and different alphabetic suffixes (i.e., “a”, “b”, “c” and “d”) are used for each of the different embodiments. At times, a detailed description of a part is omitted with the understanding that one may review the description relating to like parts of the other embodiments.

[0032] The headlamp adjuster 100 a shown in FIGS. 2 and 3 includes an adjuster output shaft 104 a which is configured for engagement with a reflector 24 of a headlamp assembly 12 (see FIG. 1). Specifically, the adjuster output shaft 104 a provides a threaded shaft portion 106 a and a ball portion 108 a at one end for engagement in a corresponding socket in a reflector 24 (see FIG. 1, and above description, for example; see also FIG. 12 which shows an adjuster output shaft 104 c which is identical to adjuster output shaft 104 a).

[0033] The headlamp adjuster 100 a also includes a housing 110 a, and the adjuster output shaft 104 a extends from a shaft hole 112 a in a bushing 150 a which is disposed in the housing 110 a. The housing 110 a is preferably mountable to the headlamp assembly or to some other structure (see FIG. 1), such as a frame-like structure, which is generally proximate the headlamp assembly. Preferably, the headlamp adjuster 100 a is “twist lock” mounted, such that the headlamp adjuster 100 a is mountable to a headlamp assembly 12 by inserting an end 114 a of the housing 110 a into an aperture in a housing 20 of the headlamp assembly 12 (see FIG. 1), and rotating the housing 110 a of the headlamp adjuster 100 a relative to the headlamp assembly 12 through a 120° (one third) rotation. To this end, the housing 110 a preferably includes tabs 116 a (shown in FIG. 2, but omitted from FIG. 1) for engaging corresponding structure in the aperture in the housing 20 of the headlamp assembly 12.

[0034] Preferably, a sealing member (not shown in connection with the headlamp adjuster 100 a, but shown as part 118 c in connection with headlamp adjuster 100 c illustrated in FIG. 12), such as an elastomeric sealing ring formed of R7744 Silicone, is disposed generally proximate the end 114 a of the housing 110 a. Preferably, when the headlamp adjuster 100 a is installed in the aperture in the housing 20 of the headlamp assembly 12, the sealing member engages the housing 20 of the headlamp assembly 12 to provide an axial force between the housing 20 of the headlamp assembly 12 and the housing 110 a of the headlamp adjuster 100 a and generally reduces the amount of moisture which enters the headlamp assembly 12 through the aperture in the housing 20 of the headlamp assembly 12 and provides axial detent force for rotary lock. As will be described more fully later herein, once the headlamp adjuster 100 a is properly mounted and engaged with the reflector 24, the headlamp adjuster 100 a can be manipulated to cause the adjuster output shaft 104 a to translate relative to the housing 110 a and effect an adjustment to the position of the reflector 24.

[0035] The housing 110 a may be formed of, for example, Zytel 70G13HS1L, and the adjuster output shaft 104 a may be formed of, for example, Delrin 570 or Zamac-3 (die casting) with a finish of Zinc/yellow dichromate. Regardless, preferably the adjuster output shaft 104 a is easy to mold with plastic or die cast, and is relatively low cost.

[0036] As shown in FIG. 2, preferably the adjuster output shaft 104 a has a retaining member 120 a, such as a retaining ring, thereon. Preferably, the retaining member 120 a is “snapped” onto the adjuster output shaft 104 a. While the end 122 a of the adjuster output shaft 104 a opposite the ball portion 108 a limits retraction of the adjuster output shaft 104 a into the housing 110 a by nature of contact between the end 122 a of the adjuster output shaft 104 a and a rear internal stop wall 124 a in the housing 110 a, the retaining member 120 a disposed on the adjuster output shaft 104 a limits extension of the adjuster output shaft 104 a from the housing 110 a by nature of contact between the retaining member 120 a and a forward internal stop wall 126 a in the housing 110 a (this position is shown in phantom in FIG. 2).

[0037] An output gear 130 a is seated in the housing 110 a, and the output gear 130 a generally coaxially receives the adjuster output shaft 104 a through a central bore 132 a in the output gear 130 a. Preferably, the central bore 132 a of the output gear 130 a is tapped such that it threadably engages the threaded portion 106 a of the adjuster output shaft 104 a. As a result, rotation of the output gear 130 a in the housing 110 a causes the adjuster output shaft 104 a to translate generally axially in the housing 100 a when rotation is prevented by the flats 162 a, as seen in FIG. 3, or as will be described more fully later herein, causes the adjuster output shaft 104 a to rotate relative to the housing 100 a.

[0038] An input gear 134 a is driveably engaged with the output gear 130 a such that rotation of the input gear 134 a causes the output gear 130 a to rotate. Specifically, preferably external surfaces 136 a and 138 a of the input gear 134 a and output gear 130 a, respectively, provide gear teeth with engage each other. Preferably, a drive shaft portion 140 a of the input gear 134 a extends from an aperture 142 a in a cover 144 a of the housing 110 a, and is configured to be engaged by a tool (not shown) to effect rotation of the input gear 134 a, and therefore rotation of the output gear 130 a in the housing 110 a. As shown, an o-ring may be provided between the cover 144 a and the input gear 134 to provide a seal therebetween.

[0039] Preferably the adjuster output shaft 104 a not only extends through the central bore 132 a in the output gear 130 a, but also extends through a central bore 148 a in a bushing 150 a which is also disposed in the housing 110 a. A flange or tab 152 a on the cover 144 a engages a recess 154 a on the exterior surface of the bushing 150 a. This engagement generally prevents the bushing 150 a from moving generally axially within the housing 110 a while allowing the bushing 150 a to rotate within the housing.

[0040] As shown in FIGS. 3 and 8, preferably the adjuster output shaft 104 a extends from an opening 156 a in the end 158 a of the bushing 150 a, and the opening 156 a in the end 158 a of the bushing 150 a is shaped such that it generally corresponds to the cross-sectional area of the adjuster output shaft 104 a. Specifically, preferably the opening 156 a in the end 158 a of the bushing 150 a is shaped such that it provides opposing walls 160 a which are configured to engage flat surfaces 162 a (i.e., “bi-flats”) on the adjuster output shaft 104 a. The engagement between the opposing walls 160 a and the flat surfaces 162 a of the adjuster output shaft 104 a provides that the adjuster output shaft 104 a is generally prevented from rotating relative to the bushing 150 a. Therefore, for the adjuster output shaft 104 a to rotate relative to the housing 110 a, the bushing 150 a must also be allowed to rotate relative to the housing 110 a.

[0041] Preferably, the bushing 150 a is formed of plastic or some other relatively flexible material. As shown in FIGS. 2-9, the bushing 150 a includes two diametrically-opposed flexible detents 166 a which are preferably molded as part of the bushing 150 a. As shown in FIGS. 2 and 3, the bushing 150 a is journalled within the housing 110 a, and the housing 110 a contains a plurality of static detents 170 a (see FIG. 3) which are formed around the shaft hole 112 a in the end 114 a of the housing 110 a. The flexible detents 166 a on the bushing 150 a are engageable with and disengageable from the static detents 170 a on the housing 110 a. When the flexible detents 166 a of the bushing 150 a are engaged with the static detents 170 a of the housing 110 a, the bushing 150 a is prevented from rotating relative to the housing 110 a. In contrast, when the flexible detents 166 a of the bushing are disengaged from the static detents 170 a of the housing 110 a, the bushing 150 a can rotate relative to the housing 110 a. Therefore, because of the engagement between the walls 160 a at the opening 156 a in the end 158 a of the bushing 150 a and the flat surfaces 162 a on the adjuster output shaft 104 a, the adjuster output shaft 104 a cannot rotate in the housing 110 a so long as the flexible detents 166 a of the bushing 150 a are engaged with the static detents 170 a of the housing 110 a. In contrast, the adjuster output shaft 104 a can rotate, along with the bushing 150 a, in the housing 110 a when the flexible detents 166 a of the bushing 110 a are disengaged from the static detents 170 a of the housing 110 a.

[0042] In operation, the input gear 134 a of the headlamp adjuster 100 a is rotated (such as by using a tool on the drive shaft portion 140 a) to change the position of the reflector. As the input gear 134 a is rotated, the output gear 130 a rotates and causes the adjuster output shaft 104 a to translate axially in the housing 110 a, thereby changing the position of the reflector. So long as the end 122 a of the adjuster output shaft 104 a does not move into engagement with the rear stop wall 124 a in the housing 110 a, and the retaining member 120 a disposed on the adjuster output shaft 104 a does not move into engagement with the forward stop wall 126 a in the housing 100 a, the flexible detents 166 a of the bushing 150 a remain engaged with the static detents 170 a on the housing 110 a, and the bushing 150 a and adjuster output shaft 104 a are prevented from rotating relative to the housing 110 a. Hence, so long as the end 122 a of the adjuster output shaft 104 a does not move into engagement with the rear stop wall 124 a in the housing 110 a, and the retaining member 120 a disposed on the adjuster output shaft 104 a does not move into engagement with the forward stop wall 126 a in the housing 110 a, rotation of the input gear 134 a causes the adjuster output shaft 104 a to translate axially in the housing 110 a, as opposed to rotate in the housing 110 a.

[0043] Once the input gear 134 a has been rotated enough such that either the end 122 a of the adjuster output shaft 104 a moves into engagement with the rear stop wall 124 a in the housing 110 a or the retaining member 120 a disposed on the adjuster output shaft 104 a moves into engagement with the forward stop wall 126 a in the housing 110 a, the flexible detents 166 a on the bushing 150 a disengage from the static detents 170 a on the housing 110 a and continued rotation of the input gear 134 a in the same direction causes the adjuster output shaft 104 a (and bushing 150 a) to rotate in the housing 110 a, as opposed to continue to translate axially, further moving the reflector. Hence, over-travel of the adjuster output shaft 104 a in either direction is prevented by a clutch mechanism which is provided by the detents 166 a on the bushing 150 a and the static detents 170 a of the housing 110 a.

[0044] Preferably, the range of axial travel of the adjuster output shaft 104 a is limited to six rotations of the input gear 134 a, and during this range of travel, the adjuster output shaft 104 a travels about 12 mm. When the input gear 134 a is rotated and the retaining member 120 a on the adjuster output shaft 104 a moves into engagement with the forward stop wall 126 a in the housing 110 a, the tension in the adjuster output shaft 104 a increases due to the output gear 130 a being constrained in the housing, bearing on surface 176 a. This axial tension effectively couples the output gear 130 a to the adjuster output shaft 104 a by means of friction at the thread interfaces between the output gear 130 a and the adjuster output shaft 104 a. When this occurs, the adjuster output shaft 104 a tends to rotate the bushing 150 a, thereby causing the flexible detents 166 a of the bushing 150 a to disengage from the static detents 170 a on the housing 110 a. Thereafter, as the input gear 134 a continues to be rotated in the same direction, the bushing 150 a is free to rotate in the housing 110 a, and the adjuster output shaft 104 a, instead of continuing to translate, rotates along with the bushing 150 a. Therefore, the adjuster output shaft 104 a does not over-travel in the extending direction (i.e., toward the reflector) as the input gear 134 a continues to be rotated in the same direction.

[0045] Turning the input gear 134 a in the opposite direction releases the axial tension between the adjuster output shaft 104 a and the output gear 130 a. Hence, the friction coupling reduces and the torque on the bushing 150 a reduces. When this occurs, the flexible detents 166 a on the bushing 150 a re-engage the static detents 170 a on the housing 110 a and the bushing 150 a is prevented from continuing to rotate relative to the housing 110 a. When the bushing 150 a stops rotating, the adjuster output shaft 104 a also stops rotating, and instead begins to translate axially away from the stop interference.

[0046] As the input gear 134 a continues to be rotated in the same direction such that the adjuster output shaft 104 a sufficiently axially translates causing the end 122 a of the adjuster output shaft 104 a to move into contact with the rear stop wall 124 a in the housing 110 a, the tension in the adjuster output shaft 104 a increases due to the output gear 130 a being constrained in the housing 110 a, bearing on surface 178 a. This axial tension effectively couples the output gear 130 a to the adjuster output shaft 104 a by means of friction at the thread interfaces between the output gear 130 a and the adjuster output shaft 104 a. When this occurs, the adjuster output shaft 104 a tends to rotate the bushing 150 a, thereby causing the flexible detents 166 a of the bushing 150 a to disengage from the static detents 170 a on the housing 110 a. Thereafter, as the input gear 134 a continues to be rotated in the same direction, the bushing 150 a is free to rotate in the housing 110 a, and the adjuster output shaft 104 a, instead of continuing to translate, rotates along with the bushing 150 a. Therefore, the adjuster output shaft 104 a does not over-travel in the retracting direction (i.e., away from the reflector) as the input gear 134 a continues to be rotated in the same direction.

[0047] Turning the input gear 134 a in the opposite direction releases the axial tension between the adjuster output shaft 104 a and the output gear 130 a. Hence, the friction coupling reduces and the torque on the bushing 150 a reduces. When this occurs, the flexible detents 166 a on the bushing 150 a re-engage the static detents 170 a on the housing 110 a and the bushing 150 a is prevented from continuing to rotate relative to the housing 110 a. When the bushing 150 a stops rotating, the adjuster output shaft 104 a also stops rotating, and instead begins to translate axially away from the stop interference.

[0048] Hence, over-travel of the adjuster output shaft 104 a in either direction is prevented by a clutch mechanism which is provided by the detents 166 a on the bushing 150 a and the static detents 170 a of the housing 110 a. The detent force is important to the clutch mechanism function. One having ordinary skill in the art would recognize that a higher initial coupling (frictional) between the adjuster output shaft 104 a and the output gear 130 a would allow for more margin to meet clutch slip torque which is determined by the detenting.

[0049] The headlamp adjuster 100 b shown in FIGS. 10 and 11 is similar to the headlamp adjuster 100 a shown in FIGS. 2 and 3. Therefore, similar reference numerals are used to identify similar parts, and the alphabetic suffix “b” is used. At times, a detailed description of a part is omitted with the understanding that one may review the description relating to a corresponding part of one of the other embodiments.

[0050] The headlamp adjuster 100 b shown in FIGS. 10 and 11 includes an adjuster output shaft 104 b having a ball portion 108 b, a threaded portion 106 b, and flat surface portions 162 b (i.e., “bi-flats”), and the adjuster output shaft 104 b has a retaining member 120 b thereon. The headlamp adjuster 10 b, like headlamp adjuster 100 a, includes a housing 110 b, a cover 144 b and a sealing member 143 b. As shown in FIG. 11 (but omitted from FIG. 10), like the housing of headlamp adjuster 100 a, preferably the housing 110 b of headlamp adjuster 100 b has tabs 116 b thereon which engage corresponding structure in the aperture in the housing 20 of the headlamp assembly 12 (see FIG. 1), thereby providing that the headlamp adjuster 100 b is “twist lock” mountable. The housing 100 b includes a shaft hole 112 b from which the adjuster output shaft 104 b extends. As shown in FIG. 11, the shaft hole 112 b is shaped such that it generally corresponds to the cross-sectional area of the adjuster output shaft 104 b. Specifically, preferably the shaft hole 112 b provides opposing walls 160 b which are configured to engage the flat surfaces 162 b (i.e., the “bi-flats”) on the adjuster output shaft 104 b. The engagement between the opposing walls 160 b and the flat surfaces 162 b of the adjuster output shaft 104 b provides that the adjuster output shaft 104 b is generally prevented from rotating relative to the housing 110 b.

[0051] As shown in FIG. 10, the headlamp adjuster 100 b, like headlamp adjuster 100 a, includes an input gear 134 b and an output gear 130 b. However, unlike headlamp adjuster 100 a, the output gear 130 b of headlamp adjuster 100 b is not threadably engaged with the adjuster output shaft 104 b. Instead, a clutch bushing 150 b is threadably engaged with the adjuster output shaft 104 b, and the output gear 130 b has a free running fit on the external surface of the clutch bushing 150 b. The clutch bushing 150 b includes a shoulder 180 b, and a friction coupling member 182 b, such as an o-ring formed of nitrile, which is compressed between the output gear 130 b and the shoulder 180 b of the clutch bushing 150 b. In addition to providing a friction coupling, the elastomeric nature of the o-ring also provides a biasing action. As shown in FIG. 10, the clutch bushing 150 b, elastomeric member 182 b, and output gear 130 b are disposed in a seat 184 b in the housing 110 b. The compressed elastomeric member 182 b provides a friction coupling between the threaded clutch bushing 150 b and the output gear 130 b, which can slip under an overload condition.

[0052] In operation, the input gear 134 b of the headlamp adjuster 100 b is rotated (such as by using a tool) to change the position of the reflector. As the input gear 134 b is rotated, the output gear 130 b rotates and, because of the friction coupling between the output gear 130 b and clutch bushing 150 b, provided by the compressed friction coupling member 182 b, the clutch bushing 150 b also rotates. Rotation of the clutch bushing 150 b causes the adjuster output shaft 104 b to translate due to the threadable engagement between the output gear 130 b and adjuster output shaft 104 b and the engagement of the adjuster output shaft 104 b with the opposing walls 160 b at the shaft hole 112 b in the housing 110 b (see FIG. 11). As the adjuster output shaft 104 b translates axially, the position of the reflector changes. So long as the end 112 b of the adjuster output shaft 104 b does not move into engagement with a rear stop wall 124 b in the housing 110 b, and the retaining member 120 b disposed on the adjuster output shaft 104 b does not move into engagement with a forward stop wall 126 b in the housing 110 b, rotation of the input gear 134 b causes the clutch bushing 150 b to rotate and the adjuster output shaft 104 b to translate axially.

[0053] Once the input gear 134 b has been rotated enough such that either the end 122 b of the adjuster output shaft 104 b moves into engagement with the rear stop wall 124 b in the housing 110 b or the retaining member 120 b disposed on the adjuster output shaft 104 b moves into engagement with the forward stop wall 126 b in the housing 110 b, the output gear 130 b will slip relative to the clutch bushing 150 b and the clutch bushing 150 b will not rotate. That is to say, an overload condition will exist, such that continued attempt to rotate the input gear 134 b, will overcome the friction coupling provided by the elastomeric member 182 b and output gear 130 b will in effect “slip” relative to the clutch bushing 150 b. Thus, the input gear 134 b and the output gear 130 b can rotate without movement of the output shaft 104 b. Hence, the adjuster output shaft 104 b does not continue to translate axially. The clutch action between the output gear 130 b and the clutch bushing 150 b when the end 122 b of the adjuster output shaft 104 b moves into engagement with the rear stop wall 124 b in the housing 110 b or the retaining member 120 b disposed on the adjuster output shaft 104 b moves into engagement with the forward stop wall 126 b in the housing 110 b provides that over-travel of the adjuster output shaft 104 b in either direction is prevented.

[0054] Preferably, the range of axial travel of the adjuster output shaft 104 b is limited to six rotations of the input gear 134 b, and during this range of travel, the adjuster output shaft 104 b travels about 12 mm. When the input gear 134 b is rotated and the retaining member 120 b on the adjuster output shaft 104 b moves into engagement with the forward stop wall 126 b in the housing 110 b, the tension in the adjuster output shaft 104 b increases due to the output gear 130 b being constrained in the housing, bearing on surface 176 b. This axial tension effectively couples the clutch bushing 150 b to the adjuster output shaft 104 b by means of friction at the thread interfaces between the clutch bushing 150 b and the adjuster output shaft 104 b. When this occurs, further rotation of the input gear 134 b causes the output gear 130 b to slip relative to the clutch bushing 150 b, and the adjuster output shaft 104 b no longer translates axially. Therefore, the adjuster output shaft 104 b does not over-travel in the extending direction (i.e., toward the reflector) as the input gear 134 continues to be rotated in the same direction.

[0055] Turning the input gear 134 b in the opposite direction releases the axial tension between the adjuster output shaft 104 b and the clutch bushing 150 b. Hence, the friction coupling reduces, and the clutch bushing 150 b begins to move along with the output gear 130 b, and the adjuster output shaft 104 b begins to translate axially.

[0056] As the input gear 134 b continues to be rotated in the same direction such that the adjuster output shaft 104 b sufficiently axially translates causing the end 122 b of the adjuster output shaft 104 b to move into contact with the rear stop wall 124 b in the housing 110 b, the tension in the adjuster output shaft 104 b increases due to the clutch bushing 150 b being constrained in the housing 110 b, bearing on surface 178 b. This axial tension effectively couples the clutch bushing to the adjuster output shaft 104 b by means of friction at the thread interfaces between the clutch bushing 150 b and the adjuster output shaft 104 b. When this occurs, further rotation of the input gear 134 b causes the output gear 130 b to slip relative to the clutch bushing 150 b, and the adjuster output shaft 104 b no longer translates axially. Therefore, the adjuster output shaft 104 b does not over-travel in the retracting direction (i.e., away from the reflector) as the input gear 134 b continues to be rotated in the same direction.

[0057] Turning the input gear 134 b in the opposite direction releases the axial tension between the adjuster output shaft 104 b and the clutch bushing 150 b. Hence, the friction coupling reduces, and the clutch bushing 150 b begins to move again along with the output gear 130 b, and the adjuster output shaft 104 b begins to translate axially.

[0058] Hence, over-travel of the adjuster output shaft 104 b in either direction is prevented by a clutch mechanism which is provided by the interaction between the output gear 130 b, the elastomeric member 182 b and the clutch bushing 150 b.

[0059] The headlamp adjuster 100 c shown in FIG. 12 is similar to the headlamp adjusters 100 a and 100 b shown in FIGS. 2-3 and 10-11, respectively. Therefore, similar reference numerals are used to identify similar parts, and the alphabetic suffix “c” is used. At times, a detailed description of a part is omitted with the understanding that one may review the description relating to a corresponding part of one of the other embodiments.

[0060] The headlamp adjuster 100 c shown in FIG. 12 includes an adjuster output shaft 104 c having a ball portion 108 c, a threaded portion 106 c, and flat surface portions 162 c (i.e., “bi-flats”), and the adjuster output shaft 104 c has a retaining member 120 c thereon. Preferably, the retaining member 120 c is crimped onto the adjuster output shaft 104 c (represented with force arrows “F” in FIG. 15) so that the retaining member 120 c does not have a tendency to rotate relative to the adjuster output shaft 104 c. The headlamp adjuster 100 c, like headlamp adjusters 100 a and 100 b, includes a housing 110 c, a cover 144 c and a sealing member 143 c, and preferably includes a sealing member 118 c proximate the front 114 c of the housing 110 c for sealing against the housing 20 of the headlamp assembly 12 (see FIG. 1). As shown, preferably the housing 110 c of headlamp adjuster 100 c has tabs 116 c thereon which engage corresponding structure in the aperture in the housing 20 of the headlamp assembly 12, thereby providing that the headlamp adjuster 100 c is “twist lock” mountable. The housing 110 c includes a shaft hole 112 c from which the adjuster output shaft 104 c extends. As shown in FIGS. 12 and 14, a tower 190 c is attached to the rear of the housing 110 c, and the end 122 c of the adjuster output shaft 104 c extends into the tower 190 c.

[0061] As shown in FIG. 12, the headlamp adjuster 100 c, like headlamp adjuster 100 b, includes an input gear 134 c, an output gear 130 c, a clutch bushing 150 c and a friction coupling member 182 c, such as an elastomeric washer. However, unlike the headlamp adjuster 100 b shown in FIGS. 10 and 11, the headlamp adjuster shown in FIG. 12 includes a clutch mechanism which has an additional member in the form of a friction washer 196 c which is disposed intermediate the output gear 130 c and the clutch bushing 150 c. The configuration of the output gear 130 c, friction coupling member 182 c, friction washer 196 c and clutch bushing 150 c is shown in FIG. 13. As shown, the output gear 130 c provides a seat 198 c for receiving the elastomeric friction coupling member 182 c, and the friction washer 196 c is provided between the elastomeric member 182 c and the clutch bushing 150 c. Preferably, the output gear 130 c has a free running fit on the external surface of the extension on the clutch bushing 150 c, and the compressed friction coupling member 182 c provides a friction coupling between the clutch bushing 150 c and the output gear 130 c. The biasing action provided by the elastomeric member 182 c, forces the friction washer 196 c into engagement with clutch bushing 150 c. Preferably, the friction washer 196 c is formed of a flexible non-asbestos molded material with medium to high friction, good stability and good wear characteristics. Specifically, the friction washer 196 c may be obtained from Great Lakes Friction Products, Inc. 8601 North 43rd Street, Milwaukee, Wis. 53209 pursuant to Engineering Product Data Sheet GL134-142. The friction washer 196 c effectively acts as a barrier to adhesion between the elastomeric member 182 c and the clutch bushing 150 c. In other words, the friction washer 196 c will have a tendency to slip relative to the clutch bushing 150 c before the elastomeric member 182 c has a tendency to slip between the friction washer 196 c and the output gear 130 c. As a result, a more constant breakaway torque (between the clutch bushing 150 c and output gear 130 c) is maintained over time compared to the embodiment wherein the friction washer 196 c is not utilized (i.e., as shown in FIG. 10). It should be noted however, that while it is preferred that the clutch action take place between the friction washer 196 c and clutch bushing 150 c, slippage may also occur between member 182 c and the friction washer 196 c.

[0062] As shown in FIG. 12, a nut 200 c is provided in a seat 202 c in the housing 110 c. Preferably, unlike with headlamp adjuster 100 b, the clutch bushing 150 c is not threadably engaged with the adjuster output shaft 104 c. Instead, the adjuster output shaft 104 c is threadably engaged with the nut 200 c which is seated in the housing 110 c, as shown in FIG. 14, and the clutch bushing 150 c provides opposing walls 160 c (see FIG. 12) which engage the flat portions 162 c of the adjuster output shaft 104 c. Hence, the adjuster output shaft 104 c cannot rotate relative to the clutch bushing 150 c, and rotation of the clutch bushing 150 c causes the adjuster output shaft 104 c to also rotate, however the shaft 104 c is free to translate relative to the bushing 150 c. The threadable engagement between the nut 200 c which is seated in the housing 100 c (see FIG. 14) and the adjuster output shaft 104 c causes the adjuster output shaft 104 c to translate axially when the adjuster output shaft 104 c rotates. Therefore, rotation of the clutch bushing 150 c causes the adjuster output shaft 104 c to translate axially, thereby changing the position of the reflector which is engaged with the adjuster output shaft 104 c (see FIG. 1).

[0063] In operation, the input gear 134 c of the headlamp adjuster 100 c is rotated (such as by using a tool) to change the position of the reflector. As the input gear 134 c is rotated, the output gear 130 c rotates and, because of the friction coupling between the output gear 130 c, elastomeric member 182 c, friction washer 196 c and clutch bushing 150 c, the clutch bushing 150 c also rotates. Rotation of the overall clutch mechanism, including bushing 150 c causes the adjuster output shaft 104 c to translate due to the threadable engagement between the adjuster output shaft 104 c and the nut 200 c which is seated in the housing 110 c (see FIGS. 12 and 14). As the adjuster output shaft 104 c translates axially, the position of the reflector changes. So long as the end 122 c of the adjuster output shaft 104 c does not move into engagement with a rear stop wall 124 c in the tower 190 c, and the retaining member 120 c disposed on the adjuster output shaft 104 c (see FIGS. 12 and 14) does not move into engagement with a forward stop wall 126 c on the housing 110 c, rotation of the input gear 134 c causes the clutch bushing 150 c to rotate and the adjuster output shaft 104 c to translate axially.

[0064] Once the input gear 134 c has been rotated enough such that either the end 122 c of the adjuster output shaft 104 c moves into engagement with the rear stop wall 124 c in the tower 190 c or the retaining member 120 c disposed on the adjuster output shaft 104 c moves into engagement with the forward stop wall 126 c on the housing 110 c, the output gear 130 c, elastomeric member 182 c and friction washer 196 c will slip relative to the clutch bushing 150 c and the clutch bushing 150 c will not rotate. That is to say, an overload condition will exist, such that continued attempt to rotate the input gear 134 c, will overcome the friction coupling provided by the elastomeric member 182 c and output gear 130 c will in effect “slip” relative to the clutch bushing 150 c. Thus, the input gear 134 c and the output gear 130 c can rotate without movement of the output shaft 104 c. Hence, the adjuster output shaft 104 c does not continue to translate axially. The clutch action between the output gear 130 c and the clutch bushing 150 c when the end 122 c of the adjuster output shaft 104 c moves into engagement with the rear stop wall 124 c in the tower l90 c or the retaining member 120 c disposed on the adjuster output shaft 104 c moves into engagement with the forward stop wall 126 c on the housing 110 c provides that over-travel of the adjuster output shaft 104 c in either direction is prevented.

[0065] Preferably, the range of axial travel of the adjuster output shaft 104 c is limited to six rotations of the input gear 134 c, and during this range of travel, the adjuster output shaft 104 c travels about 12 mm. When the input gear 134 c is rotated and the retaining member 120 c on the adjuster output shaft 104 c moves into engagement with the forward stop wall 126 c on the housing 110 c, the tension in the adjuster output shaft 104 c increases due to the output gear 130 c being constrained in the housing 110 c. This axial tension effectively couples the clutch bushing 150 c to the adjuster output shaft 104 c by means of friction at the interface therebetween. When this occurs, further rotation of the input gear 134 c causes the output gear 130 c, elastomeric member 182 c and friction washer 196 c to slip relative to the clutch bushing 150 c, and the adjuster output shaft 104 c no longer translates axially. Therefore, the adjuster output shaft 104 c does not over-travel in the extending direction (i.e., toward the reflector) as the input gear 134 c continues to be rotated in the same direction.

[0066] Turning the input gear 134 c in the opposite direction releases the axial tension between the adjuster output shaft 104 c and the clutch bushing 150 c. Hence, the friction coupling reduces, and the clutch bushing 150 c begins to move along with the output gear 130 c, and the adjuster output shaft 104 c begins to translate axially.

[0067] As the input gear 134 c continues to be rotated in the same direction such that the adjuster output shaft 104 c sufficiently axially translates causing the end 122 c of the adjuster output shaft 104 c to move into contact with the rear stop wall 124 c in the tower 190 c, the tension in the adjuster output shaft 104 c increases due to the clutch bushing 150 c being constrained in the housing 110 c. This axial tension effectively couples the clutch bushing 150 c to the adjuster output shaft 104 c by means of friction at the interface therebetween. When this occurs, further rotation of the input gear 134 c causes the output gear 130 c, elastomeric member 182 c and friction washer 196 c to slip relative to the clutch bushing 150 c, and the adjuster output shaft 104 c no longer translates axially. Therefore, the adjuster output shaft 104 c does not over-travel in the retracting direction (i.e., away from the reflector) as the input gear 134 c continues to be rotated in the same direction.

[0068] Turning the input gear 134 c in the opposite direction releases the axial tension between the adjuster output shaft 104 c and the clutch bushing 150 c. Hence, the friction coupling reduces, and the clutch bushing 150 c begins to move again along with the output gear 130 c, and the adjuster output shaft 104 c begins to translate axially.

[0069] Hence, over-travel of the adjuster output shaft 104 c in either direction is prevented by a clutch mechanism which is provided by the interaction between the output gear 130 c, the elastomeric member 182 c, the friction washer 196 c and the clutch bushing 150 c.

[0070] The headlamp adjuster 100 d shown in FIG. 16 is very similar to the headlamp adjuster 100 c shown in FIG. 12. In fact, the only difference is that the headlamp adjuster 100 d shown in FIG. 16 includes a collar stop 240 d on the adjuster output shaft 104 d, proximate the ball portion 108 d. Preferably, the collar stop 240 d is generally tubular with an inside diameter greater than the outside diameter of the threaded portion 106 d of the adjuster output shaft 104 d. Preferably, the collar stop 240 d is disposed on the adjuster output shaft 104 d such that the collar stop 240 d generally contacts the ball portion 108 d. Ideally, the collar stop 240 d is a relatively low cost part, and may be made, for example, by cutting tubing to a pre-determined length (“L” in FIG. 16). In such case, the length (L) may be variable depending on the desired travel of the adjuster output shaft 104 d (i.e. depending on how far one wants the adjuster output shaft 104 d to be retractable).

[0071] While in the headlamp adjuster 100 c shown in FIG. 12 the rear wall 124 c of the tower 190 c limits travel of the adjuster output shaft 104 c in the retraction direction, in the headlamp adjuster 100 d shown in FIG. 16 the collar stop 240 d limits travel of the adjuster output shaft 104 d in the retraction direction. Specifically, when the adjuster output shaft 104 d is retracted to the fullest extent, the collar stop 240 d engages surface 242 d of the housing 110 d, thereby generally preventing the adjuster output shaft 104 d from being retracted any further. By providing a collar stop 240 d to limit travel in the retraction direction, rather than providing that the end 122 d of the adjuster output shaft 104 d bears against the internal wall 124 d of the tower 190 d, there is no risk of stressing, for example, a possible weld joint 244 d between the housing 110 d and tower 190 d.

[0072] With regard to the other direction, i.e. extension of the adjuster output shaft 104 d, the headlamp adjuster 100 d shown in FIG. 16, like the headlamp adjuster 100 c shown in FIG. 12, includes a retaining member 120 d which is crimped or otherwise engaged with the adjuster output shaft 104 d, proximate the end 122 d of the adjuster output shaft 104 d. When the adjuster output shaft 104 d is extended to the fullest extent, the retaining member 120 d which is disposed on the adjuster output shaft 104 d engages the forward stop wall 126 d on the housing 110 d, thereby generally preventing the adjuster output shaft 104 d from being extended any further. A qualified thread coating may be applied to the ball portion 108 d of the adjuster output shaft 104 d and this would restrict movement of the collar stop 240 d when the adjuster output shaft 104 d is extended and the collar stop 240 d would otherwise be free to move (i.e. along the threaded portion 106 d of the adjuster output shaft 104 d, generally away from the ball portion 108 d of the adjuster output shaft 104 d). As an alternative to the tubular form of the collar stop 240 d, the collar stop 240 d may be in the form of a split or snap ring that is applied to the shaft 104 d, generally adjacent the head 108 d.

[0073] While the headlamp adjuster 100 d shown in FIG. 16 is shown as being generally identical (other than including a collar stop 240 d) to the headlamp adjuster 100 c which is shown in FIG. 12, including having a similar clutch assembly/mechanism 250 d, it should be understood that the headlamp adjuster 100 d may not include a clutch mechanism at all, and may merely include means to prevent over-retraction and extension of the adjuster output shaft 104 d.

[0074] Each headlamp adjuster 100 a, 100 b, 100 c and 100 d is configured to generally prevent over-travel of the adjuster output shaft 104 a, 104 b, 104 c in both the extending and retracting directions. Hence, the reflector and the headlamp adjusters 100 a, 100 b, 100 c do not tend to become damaged as a result of over-rotation of the input gear 134 a, 134 b, 134 c, 134 d.

[0075] While embodiments of the present invention are shown and described, it is envisioned that those skilled in the art may devise various modifications without departing from the spirit and scope of the foregoing description. 

What is claimed is:
 1. A headlamp adjuster for adjusting a position of a reflector of a headlamp assembly, said headlamp adjuster comprising: a housing; an adjuster output shaft which extends from and is engageable with the reflector of the headlamp assembly, said adjuster output shaft being extendable and retractable; a first stop member generally engaged with said adjuster output shaft and engageable with a surface of said housing when said adjuster output shaft is retracted; and a second stop member generally engaged with said adjuster output shaft and engageable with a surface when said adjuster output shaft is extended, wherein said headlamp adjuster is configured such that in an overload condition, the adjuster output shaft is prevented from translating substantially axially.
 2. A headlamp adjuster as recited in claim 1 , further comprising an overload clutch mechanism, said overload clutch mechanism configured to generally prevent said adjuster output shaft from being over extended or over retracted.
 3. A headlamp adjuster as recited in claim 1 , further comprising an output gear engaged with said adjuster output shaft and an input gear engaged with said output gear.
 4. A headlamp adjuster as recited in claim 1 , further comprising a tower engaged with said housing, said adjuster output shaft generally extending into said housing, said first stop member engageable with said surface of said housing when said adjuster output shaft is retracted such that said adjuster output shaft does not contact said tower.
 5. A headlamp adjuster as recited in claim 1 , further comprising at least one static detent which is generally in the housing; and a bushing disposed generally in the housing and having an opening, said adjuster output shaft extending through said opening in said bushing, said bushing providing at least one flexible detent which is engaged with said at least one static detent.
 6. A headlamp adjuster as recited in claim 5 , said headlamp adjuster configured such that said adjuster output shaft and said bushing are not generally rotatable in said housing unless said first stop member on said adjuster output shaft is in contact with said surface of said housing or said second stop member on said adjuster output shaft is in contact with said surface.
 7. A headlamp adjuster as recited in claim 1 , further comprising a clutch bushing engaged with said adjuster output shaft; an output gear engaged with said clutch bushing; and an input gear engaged with said output gear.
 8. A headlamp adjuster as recited in claim 7 , said headlamp adjuster configured such that said clutch bushing is slippable relative to said output gear to prevent substantial axial translation of said adjuster output.
 9. A headlamp adjuster as recited in claim 8 , further comprising a friction coupling member engaged with said clutch bushing and with said output gear.
 10. A headlamp adjuster as recited in claim 1 , wherein said adjuster output shaft includes a ball portion, said first stop member generally engaged adjacent said ball portion when said adjuster output shaft is retracted.
 11. A headlamp adjuster as recited in claim 1 , wherein said adjuster output shaft includes a ball portion, and said first stop member comprises a collar stop which is generally engaged adjacent said ball portion when said adjuster output shaft is retracted.
 12. A headlamp adjuster as recited in claim 1 , wherein said second stop member comprises a retaining member which is crimped onto said adjuster output shaft.
 13. A headlamp adjuster as recited in claim 1 , wherein said adjuster output shaft includes a ball portion and said ball portion has a qualified thread coating thereon. 